Land Rover 90 110 Workshop Rover Manual
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ELECTRICAL EQUIPMENT - ALTERNATOR ST 1280M 86 10 I 9 1. Cover 2. Regulator 3. Rectifier 4. Drive-end bracket 5. End bearing kit 6. Rotor assembly 7. Slip ring end bearing 8. Slip rings 6 7 14 KEY TO ALTERNATOR 9. Slip ring end bracket 10. Stator 11. Brush box 12. Brushset 13. Fixing bolt -slip ring end bracket to drive-end bracket 14. Suppression capacitor 15. Surge protection diode 21
I86 I ELECTRICAL EQUIPMENT - ALTERNATOR 19 / 11ov - I 12 I ST1283M 20. Check for satisfactory field winding insulation by connecting a 110 V A.C. 15-watt test lamp betwcen either of the slip rings and the rotor body. The lamp should not light. ST1284M Stator winding 21. Due to the very low resistance of the stator windings, a practical test to determine the presence of short -circuited turns cannot be carried out without the usc of special instruments. However, in practice inter -winding short-circuiting is usually indicated by obvious signs of burning of the insulating varnish covering the windings. If this is the case, renew the stator assembly without the need for further testing. 22. Check continuity of stator windings, by first connecting any two of the three stator winding connecting cables in scries with a 12 V battery- operated tcst lamp, of not less than 36 watts. The test lamp should light. If not, renew the stator assembly. Providing the first part of the test is satisfactory, transfer one of the test lamp leads to the other (third) cable. Again the test lamp should light. If so, proceed to insulation test. 23. Check insulation of stator windings, by connecting a 110 V A.C. 15-watt test lamp between the stator laminations and any one of the three connecting cables. The lamp should not light. I ST1285M Rectifier diodes 24. Test each of the nine diodes separately, as follows. e?.. g - Connect a 12 V battery and a 1.5 watt bulb in series with one of the diodes, one test lead being applied to the diode connecting pin and the other to the particular heat sink plate in which the diode undergoing test is soldered. Note whether lamp lights, then reverse the test lead connections. The lamp should light during one half of the test only. If any one diode test is unsatisfactory, renew the rectifier assembly. Regulator 25. Individual testing of the regulator can only be carried out with special test equipment and unless this is available the regulator must be proved by substitution. ASSEMBLE Reassembly of the alternator is a reversal of the dismantling procedure. However the following points should be observed. 26. Take care not to damage the insulation covering the winding leads when renewing the slip rings. 27. A build up of solder must not occur on the upper face of the inner slip ring. 28. Use resin cored solder only. 29. Pack the bearings with a suitable high melting point 30. Ensure that the brushes move freely in the brush 31. If the slip rings are not renewed the existing ones 32. Tighten fixings to the torque figures quoted. -2 grease. box. must be clean and smooth. continued 22
ELECTRICAL EQUIPMENT- ALTERNATOR ST1286M TIGHTENING TORQUES Through bolts ..................................................... Rectifier fixing bolts ............................................. SRE Cover ...................................................... Brush Box ....................................................... Surge Diode .................................................... Brush and Regulator fixing ................................. D/E Bearing Plate ............................................. Reg ‘IND’ Lead ................................................ Main output terminal.. ....................................... ‘IND’ terminal nuts ........................................... Shaft nut ............................................................ Sundry screws: Capacitor.. ...................................................... NUTS: 4.5 - 6.2 Nm (3.3 - 4.6 Ibf it) 27.2 - 47.5 Nm (20.0 - 35.0 Ibf ft) 3.4 - 3.96 Nm (2.5 - 2.9 Ibf ft) 1.7-2.25” (1.3- 1.7Ibfft) 3.4 - 3.96 Nm (2.5 - 2.9 Ibf ft) 3.4 - 3.96 Nm (2.5 - 2.9 Ibf ft) 3.61 - 4.74 Nm (2.7 - 3.5 Ibf ft) 1.7 - 2.25 Nm (1.3 - 1.7 Ibf ft) 4.7 - 5.7 Nm (3.5 - 4.2 Ibf ft) 1.1 - 1.36 Nm (9.7 - 12.0 lbf in) 3.96 - 5.08 Nm (2.9 - 3.7 Ibf ft) 3.61 - 4.74 Nm (2.7 - 3.5 Ibf ft) .:... .. .... .I/ , .. ..:: .. .:.a ... 23
86 ALTERNATOR OVERHAUL - Lucas A12745 ELECTRICAL EQUIPMENT- ALTERNATOR Description The model A127 alternator is a three phase, field sensed unit, the rotor and stator windings generate three phase alternating current (AC) which is rectified to direct current (DC). The electronic voltage regulator unit controls the alternator output voltage by high frequency switching of the rotor field circuit. It is essential that good electrical connections are maintained at all times. Of particular importance are those in the charging circuit (including those at the battery) which should be occasionally inspected to see that they are clean and tight. In this way any significant increase in circuit resistance can be prevented. Do not disconnect battery cables while the engine is running or damages to the semi-conductor devices may occur. It is also inadvisable to break or make any connections in the alternator charging and control circuits while the engine is running. The model 21TR electronic voltage regulator employs micro-circuit techniques resulting in improved performance under difficult service conditions. The whole assembly is encapsulated in silicone rubber and housed in an aluminium heat sink, ensuring complete protection against the adverse effects of temperature, dust, and moisture etc. The brushbox assembly is incorporated in the regulator unit. Surge protection is incorporated in the regulator unit. The regulating voltage is set during manufacture to give the required regulating voltage range of 13.6 to 14.4 volts, and no adjustment is necessary. The only maintenance needed is the occasional check on terminal connections and wiping with a clean dry cloth. The alternator system provides for direct connection of a charge (ignition) indicator warning light. and eliminates the need for a field switching relay or warning light control unit. As the warning lamp is connected in the charging circuit, lamp failure will cause loss of charge. Lamp should be checked regularly and a spare carried. When using rapid charge equipment to re-charge the a battery, the battery must be disconnected from the vehicle. .-- NOTE: Alternator charging circuit - The ignition warning light is connected in series with the alternator tield circuit. Bulb failure would prevent the alternator charging, except at very high engine speed, therefore, the bulb should be checked before suspecting an alternator failure. Precautions Battery polarity is NEGATIVE EARTH, which must be maintained at all times. No separate control unit is fitted; instead a voltage regulator of micro-circuit construction is mounted on the slip ring end bracket. Battery voltage is applied to thc alternator output cable even when the ignition is switchcd off, the battery must be disconnected before commencing any work on the alternator. The battery must also be disconnected when repairs to the body structure arc being done by arc we I ci i ng . 4, ?? -. -. DISMANTLE 1. 2. 3. 4. 5. Withdraw the connectors from the alternator. Re m o vc; the a I t e r n a tor . Remove the nuts from the through bolts, disconnect the connectors and remove two suppression capacitors. Remove three screws, disconnect one lead and withdraw the regulator and brushbox assembly. Check the brush lengths by measuring length of protrusion from moulding. If dimension A is 5mm (0.20in) or less, change thc assembly. s: -d RR2218M s-. .... 24
ELECTRICAL EQUTPMENT- ALTERNATOR 186 ill* . . -2G ALTERNATOR - LUCAS A 127-65 .- . .. .. .. Service parts 1. Suppression capacitors - 2 off 2. Regula t or/Brus h box assembly 3. Through bolts 4. Slip ring end (SRE) bracket 5. Stator 6. Rectifier 7. Drive end bracket (DRE)/bearing assembly 8. noior 9. Slip ring end bearing 25
186 I ELECTRICAL EQUIPMENT - ALTERNATOR 6. Check brush spring pressure using a push type spring guage. Gauge should register 136 to 279 g (5 to 10 02) when brush is pressed until face is flush with housing. If reading is outside these limits, renew assembly. 7. Mark the relative positions of the end brackets and stator. Remove through bolts and withdraw slip ring end bracket and stator assembly. Carefully tap the mounting lugs with a mallet if necessary. 8. Remove nuts, washers and insulators from stud terminals noting their position for reassembly. Remove two screws and insulation cover and withdraw rectifier and stator from slip ring end bracket. RR22 19M w Y 9. Release the stator winding cable ends from the rectifier by applying a hot soldering iron to the terminal tags of the rectifier. Prise out the cable ends when the solder melts, and separate the rectifier and stator. Further dismantling of the rectifier is not required. 10. Check the diodes. Connect the test equipment as shown and test each diode in turn, note whether lamp lights, then reverse test lead connections. Thc lamp should light in one direction only. Rencw thc rectifier asscmbly if a faulty diode is diagnosed. 11. Visually inspect the stator windings for signs of damage or burning. Check the stator insulation using a suitable 110 volt test lamp. Connect the test leads to the laminated yoke and to each of thc three leads in turn. If test lamp lights, fit a ncw iZ 1.5W Max 13. Clean surfaces of slip rings using a solvent moistened cloth. 14. Inspect slip ring surfaces for signs of burning, remove burn marks using extra fine glasspaper. On no account should emery cloth or similar abrasives bc used, or any attcmpt made to machine the slip rings. 15. Check the insulation of the rotor field windings, using a suitablc 110 volt test lamp connccted betwccn one of the slip rings and onc of the rotor poles. If the test lamp lights, the rotor must bc rcncwed. e I RR222 1 M 16. Check the resistance/continuity of the rotor field windings by connecting an ohmmeter to the slip rings as shown. A reading of 3.2 ohms should be obtained. 17. Check condition of bearings. If signs of rubbing between rotor Doles and stator is evident, both stator. Kemove the fan and puiiey asscmbly. Piish oiit ihc rotor shaft from the bearing using a suitable prcss and remove the spacer from the shaft. bearings are excessively worn, and must be renewed. 18. Use a suitable press, applying pressure from the rear of the slip ring end bracket, to withdraw or refit the bearing. Note that the drive end oracket and bearing are only supplied as a unit. gf---; 7’ -y/ 26
ELECTRICAL EQUIPMENT- ALTERNATOR f:::,;;:: :!, ...... ,+;sir. :.: .. Assembling ...... e,.. 19. Fit the spacer and press the rotor into the drive end bracket. Tnsert the through bolts. Fit the spacer, fan, pulley and spring washer to the shaft. Fit and tighten the pulley nut to the correct torque. 20. Fit the stator and rectifier assembly to the drive end bracket in the position previously marked. 21. Fit the slip ring end bracket in the position previously marked, locating the regulator lead through its aperture. Fit the insulation cover and tighten two rectifier securing screws. 22. Fit and tighten the through bolt nuts evenly and to the correct torque. 23. Connect the lead to the regulator, locate the brushes on the slip rings and secure the regulator/ brushbox assembly, taking care not to damage the brushes. 24. Fit both suppression capacitors. 25. Refit the alternator. * ALTERNATOR DATA Manufacturer ............................................................ Type ................................... ............................ Maximum operating speed ....................... Stator winding rcsistance .................. ....................... Regulator controlled voltage ........................................ Field winding rotor poles .............. Rotor winding resistance ............................................. Brush length - new ........................ ....................... Brush spring pressure - flush with brushbox moulding ......... Polarity ................ ............................................ Maximum DC output at 6000 rev/min ............................. Stator windings .......................................................... Regulator type .......................................................... ......................... Renew regulator/brushbox assembly at ........................... TORQUE WRENCH SETTING Nm Alternator shaft nut .................................................. 50-70 Alternator rectifier screws .......................................... 3.5 Regulator/brushbox screws ........................................ 2.5 Terminal nut - main output ......................................... 4.0 Terminal nut - phase ................................................. 4.0 Alternator through bolts ............................................ 5.5 Lucas A 127/65 Negative earth 15000 rcv/min 65 amp 3 phase 0.15 ohm/phase 21TR 13.6-1 4.4V 12 3.2 ohms 17 mm (0.67 in) From 5 mm (0.20 in) 1 moulding 1.3-2.7N (4.7-9.802) Ibf ft 4.0 2.5 2.0 3.0 3.0 37-52 27
ELECTRICAL EQUIPMENT- ALTERNATOR I ALTERNATOR FUNCTIONAL CHECK The alternator contains polarity sensitive components that could be permanently damaged if subjected to incorrect polarity. Do not connect or disconnect any part of the charging circuit - including the battery leads - while the engine is running. Run the alternator with all connections made or with the unit disconnected. This operation must be performed in two parts. Thc first to prove the alternators capacity to produce current. The sccond to prove the performance of the integral regulator. Check capacity to produce current NOTE: The stated output may be exceeded slightly when the alternator is cold. To avoid misleading results, the check should be performed with the unit as near to its normal operating temperature as possible. % 1. Check drive belt adjustment. 2. Disconnect the multi-socket connector. 3. Remove the cover and provide a suitable probe and wire to enable the field winding earth brush to be earthed direct thus by-passing the regulator. 4. Provide a test circuit as shown below. A. Alternator B. Ammeter C. 12 volt battery D. Voltmeter E. Variable resistance 5. Do not connect the variable resistor across the battery for longer than is necessary to perform the check. 6. Run the engine. 7. Gradually increase the speed. At 1550 alternator rev/min (775 engine rev/min) the light should be extinguished. 28 8. Hold the speed at approximately 6000 alternator rev/min (3000 engine rev/min). Adjust the variable resistor so that the voltmeter reads 14 volts. The ammeter reading should now be approximately equal to the nominal output given in data. 9. If the ammeter reading is not correct the indication is that the alternator requires overhaul or replacement. Check control regulator NOTE: The stated output may be exceeded slightly when the alternator is cold. To avoid misleading results, the check should be performed with the unit as near to its normal operating temperature as possible. 10. Check drive belt adjustment. 11. Disconnect multi-socket connector. 12. Provide ;I test circuit as shown. r --a---- VOLTS !- +I 13. Start the engine and gradually increase the speed. At 1550 alternator rev/min (775 engine rev/min) the light should be extinguished. rev/min (3000 engine rev/min). The voltmeter reading should now be steady at 13.6 to 14.4 volts. 15. If the voltmeter reading is not steady at the above figure - and a satisfactory check capacity to y, produce current has been performed - the indication is that the control regulator should be replaced. 14. the speed at apprcjxima;c!j: 6ggg a!:ernato; g.2
Warning Light Illuminated at stand-still. extinguished at cut-in bpeed (I ,5on revhnin) but at higher speeds becomes partially illuminated again and gets progressively brighter Not illuminated hetwceti zero at 1 ,500 rev/nun Teniperature High High ALTERNATOR DOES NOT CHARGE WEAK OR IRRF,GULAR CHARGE OVER CHARGE WORN OR SLACK BELT WORN OR DIRTY BRUSHES BROKEN OR FAULTY ROTOR WINDING BREAK IN CHARGING CIRCUIT OPEN CIRCUIT OK FAULTY FIELD DIODE FAULTY REGIJLATOR 2 OR 3 RECTIFIER DIODES OFSAME POLARITY FAULTY WORN OR SLACK BELT WORN OR DIRTY BRUSHES ONE OR MORE DEFECTIVE RECTIFIER DIODES FAULTY REGULATOR FAULTY CONNECTIONS FAULTY REGULATOR FAULTY CONNECTIONS BETWEEN ALTERNATOR AND REGULATOR OPEN OR SHORT-CIRCUITED STATOR ELECTRICAL EQUIPMENT - ALTERNATOR 186 I DIODE FAULT SYSTEM Failure of one or more of the diodes will be indicated by the output of the alternator and in some instances by an abnormally high temperature and noise level. The following fault symptom chart shows how diode failure will influence alternator test results. Noise Probable Fault (Assnciated Damage) output Higher than normal at 6,000 revimin. Approximately 40A Normal Live-side main output diode open circuit. (May damage rotor field winding and regulator, overheat, brushboxes. and fuse warning light bulb) Excessive Very low at 6.000 rev/min Approximately IOA Live-side main output diode short circuit. (May darnage associated field diode) Excessive Poor at low speed Slightly below normal at 6,000 revh in. Approximately 32A Earth -side main output diode open circuit Illwninatcd at stand-still, dims appreciably at cut-in speed (I ,500 rcv/min) and gets progrcssively dimmer or may be extinguished at higher speeds Nor ni a I Field diodc open-circuit Illuminated at stand-still. dims appreciably at cut-in speed (I ,500 reviinin) and gets progi-essivcly dimmer or may be extinguished at higher speeds Normal Lower than nornial at 6,000 rev/ min. Approximately 29A Normil I Excessive Very low at all speeds above etit- in (1.500 revhin). Illuminated at stand-still. dims iit Gut-in speed (1,500 rev/min) and remains dim, but may he zxtinguished ;it very high speeds Normal Earth -side main output diode short-circuit, or witor winding short-circuit to earth Field diode short-circuit Vcry low ;it 6.000 revhnin Approximately 7A Illuminated at stand-still, dims at :ut-in spectf ( I,500 rev/min) and remains dim. but may be Normal ALTERNATOR FAULT AND DIAGNOSIS CHART NOISY ALTERNATOR WORN BELT LOOSE PULLEY LOOSE ALTERNATOR MOUNTINGS MISALIGNMENT OF PULLEYS FAULTY BEAKING ONE OR SEVERAL RECTIFIER DTODES OPEN OR SHORT-CIRC1IITEn SHORT-CIRCUITED STATOR i CHECK EACH ITEM IN TURN AND RECTIFY IF NECESSARY BEFORE PROCEEDING TO NEXT ITEM. 29
L 86 DIESEL ENGINE STARTER MOTOR (2M113) DISMANTLE TEST AND OVERHAUL Solenoid Unit ELECTRICAL EQUIPMENT - DIESEL ENGINE STARTER MOTOR 1. Disconnect link from starter terminal. 2. Unscrew and remove solenoid securing screws and withdraw the solenoid body. 3. Remove plunger complete with seal and nylon block (if fitted) by lifting front end of plunger to release it from the top of the engagement lever. Commutator end bracket 4. Remove the two brush plate securing screws. 5. Remove the two through bolts. 6. Withdraw the commutator end bracket and seal (if fitted). Note position of the dowel pegs in the end of commutator. Yoke assembly 8. Withdraw the yoke assembly complete with field coils, brushes and seal (if fitted). Drive end bracket 9. 10. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Remove the eccentric pivot pin. Withdraw the drive -end bracket by releasing engagement lever from drive operating collar whilst the bracket is being removed. continued KEY TO STARTER MOTOR COMPONENTS Solenoid Solenoid -starter link Bracket assembly - commutator end Brake assembly Brush box mounting plate assembly Brush springs Brush set Field coil assembly Engaging lever assembly Bracket assembly drive -end Retention assembly Drive Bracket assembly, intermediate Armature Bearing bush -set of three Yoke Brush plate assembly 7. Disengage the brushes and remove the brush plate assembly. 3 6 1 STl289M 30